2015 Ford F-350 Sd Fuel system Problems

The contact owns a 2015 Ford F-350. The contact stated that a certified mechanic had installed a disaster kit on the vehicle to prevent a fuel system failure. The independent mechanic later found metal shavings inside the filter going into the manifold. The independent mechanic recommended that the fuel pump be replaced. The contact was concerned that the replacement of the fuel pump with the same part would be a temporary fix. The vehicle was not yet repaired. The dealer was contacted and advised the contact to take the vehicle in for a diagnostic test. The manufacturer was not contacted. The failure mileage was approximately 81,000.

NHTSA ID

11723818

Incident

Mar 8, 2026

Mileage

81,000 mi

Failed CP4 design. $10000 to fix a known issue with a failed design that Gm had a class action lawsuit with.

NHTSA ID

11612633

Incident

Sep 4, 2024

This vehicle developed a fuel leak in the area of the top of the engine which resulted in a fire that destroyed the vehicle. I spoke to the Ford Motor Company and they said that there are no recalls or Technical Service Bulletins regarding this. I just wanted to make you aware of my experience so if anyone else experienced this it may show a pattern. Thank You

NHTSA ID

11483655

Incident

Aug 29, 2022

The contact owns a 2015 Ford F-350. The contact stated that an unknown warning code was illuminated on the screen display. The vehicle was towed to the dealer where it was diagnosed that the cold side charge tube, power stroke oil filter, and outlet tube assembly needed to be replaced. The manufacturer was notified of the failure and the contact was advised to call the NHTSA Hotline. The failure mileage was approximately 36,000.

NHTSA ID

11483536

Incident

Sep 4, 2022

Mileage

36,000 mi

1/4/2022 – TRAVELING TO SOUTHERN OHIO IN F-350. Engine light came on. Truck info screen showed Exhaust Fluid System Fault – indicating truck would lock to 50 mph within a certain number of miles, then possibly shut down. Finally got in touch with Ford dealership in Chillicothe and took truck there. They determined it was a DEF heater and pump causing the issue, and that it would be covered by Ford as an extended warranty issue. Ford decided our truck was not covered. On 1/11, Ford added a new campaign – 21M01, Reductant Heater and Sender Assembly, covering the cost of replacement of these items. We were told we needed to pay the repair and Ford would reimburse. To this date, we have not been reimbursed - in fact have pretty much been ignored. The sensor recalibration they did caused the particulate filter to fail. Ford has said they won't replace, even though service manager has said the filter failed because Ford had them recalibrate the sensor. We could have been stranded 140 miles from home because of this design fault that Ford knows about - but is not being forced to take care of. Our truck has less than 64000 miles on it and was purchased new by me in April 2014. Will you please strongly encourage Ford to stand by this defective equipment they have installed in their vehicles, as their 'customer satisfaction campaigns' do not adequately encourage them to fix these faulty issues. Volkswagen and Audi both stand by their defective equipment. Consumer wants assistance getting Ford to pay for repairs.

NHTSA ID

11457166

Incident

Jan 4, 2022

Cp4 fuel pump failure, upon failure repair was $9300.00, ford obviously knows of the problem as their is a kit that can be purchased for this catastrophic failure{fuel line replacement, fuel injection replacement, both fuel pump replacement , drop and flush fuel tank.}

NHTSA ID

11443761

Incident

Dec 30, 2020

CP4 High pressure fuel injection pump blew up, causing the truck to need a 17,000$ fuel system at 93k miles. Thankfully I had warranty with Ford- however what happens when it’s over and it goes again? Pay 17,000$ out of pocket? Ford needs to recall this just like dodge / Cummins. 17,000$ out of pocket can be crippling to the average American.

NHTSA ID

11443701

Incident

Jun 10, 2021

Check engine light came on in my 2015 F 3 50 super duty crew cab truck. Upon inspection at the Ford dealership I was told the Reductant Heater And Sender Assembly Need to be replaced at a cost of $1100. This is happening within 60 days of heat sensor recall being done. When I look into this topic this repair has a recall on it for F2 50s through F5 50’s including various years up to 2015, but the F3 50 is only up to 2012.

NHTSA ID

11442414

Incident

Dec 1, 2021

P20BA - DEF Reductant Heater Code for a defective DEF reductant heater on a 2015 F-350 6.7L diesel with 57,500 miles NOT covered under dealer emissions warranty.

NHTSA ID

11441227

Incident

Nov 21, 2021

Took truck in for smog they notified me that there is a factory recall manufacturer campaign # 21E01 , recall date 3/16/2021. Description CALIBRATION FOR NOX SENSOR AND SCR SYSTEM FAULTS

NHTSA ID

11439137

Incident

Oct 15, 2021

HAVE TO REV GAS PADDLE ON VEHICLE TO TAKE OFF..VEHICLE ALSO STALLS WHILE DRIVING DOWN THE HIGHWAY..

NHTSA ID

11396058

Incident

Dec 1, 2020

SAME PROBLEM W/ THE DEF HEATING UNIT AS ON EARLIER/SIMILAR F-SERIES TRUCKS THAT HAVE COMPELLED FORD TO ISSUE EXTENDED WARRANTY (SEE CUSTOMER SATISFACTION PROGRAM 18M01) -- A DTC208A ERROR COMES UP, INDICATING FAILURE IN THE DEF SENDER/HEATER. NOT CLEAR WHY FORD IS OMITTING THE 2015 F350 POWERSTROKES WHEN THEY'RE USING THE SAME PART AND BUILT IN THE SAME FACTORY AS THE MODELS THAT HAVE HAD THE WARRANTY EXTENDED.

NHTSA ID

11270968

Incident

Oct 18, 2019

Mileage

96,000 mi

ON MY 2115 FORD F 350 POWERSTROKE DIESEL THE CHECK ENGINE LIGHT CAME ON AND IT DE RATED THE POWER. I READ THE CEL CODE AND ITS PB20A WHICH IS A REDACTANT HEATER PERFORMANCE FAILURE. THIS PROBLEM IS COVERED UNDER WARRANTY FOR ALL MODELS 2011-14, F250-F 550 AND 2015 F450, F550 ONLY. FORD ISN'T COVERING THE F250 OF F350 IN THE 2015 YEARS. MY TRUCK MEETS THE DATE AND MANUFACTURING PLANT CRITERIA AND IT IS NO DRIVABLE BECAUSE OF THIS EMISSIONS CONTROL PART FAILURE. THE REDACDANT HEATER KEEPS THE DIESEL EXHAUST FLUID FROM FREEZING AND RENDERS THE VEHICLE UN DRIVABLE WHEN IT FALIS.

NHTSA ID

11265376

Incident

Sep 28, 2019

Mileage

97,000 mi

I WAS DRIVING OUT OF STATE (NY) WHEN AN ALERT STATED "LOW FUEL PRESSURE) AND THE VEHICLE SLOWED TO 5-10 MPH WHILE TRAVELING ON THE INTERSTATE. UPON EXITING, THE VEHICLE STOPPED RUNNING LEAVING ME AND MY FAMILY STRANDED. I HAD IT TOWED TO A LOCAL SHOP WHICH INFORMED ME THE BOSCH HIGH PRESSURE FUEL PUMP WAS NOT DELIVERING THE REQUIRED PRESSURE (/,000 PSI). UPON CONTACTING THE FORD DEALERSHIP WHERE THE VEHICLE WAS PURCHASED, I WAS INFORMED THE VEHICLE EXCEEDED WARRANTY MILES (100,000/129,239) AND THE COST OF THE PUMP WAS $1,245 WITH EXCHANGE PRIOR TO LABOR CHARGES. IN ALL, FORD DEALER WANTS NEARLY $5,000 TO REPAIR THE PUMP WHICH WAS POORLY DESIGNED.

NHTSA ID

11254280

Incident

Aug 17, 2019

Mileage

129,239 mi

I OWN A 2015 FORD F-350SD WITH APPROXIMATELY 42,000 MILES THAT I BOUGHT FROM THE FORD DEALER IN SEPTEMBER OF 2018. SO, I HAVEN'T EVEN OWNED THE TRUCK A YEAR YET. ON JULY 12, 2019 I WAS DRIVING DOWN I15 HEADED TO A CAMPING TRIP. ALL OF A SUDDEN, MY CHECK ENGINE LIGHT CAME ON AND THEN A MESSAGE SAYING REDUCED ENGINE POWER AND MY TRUCK WENT FROM 70MPH TO 5MPH AND JUST BARELY GOT ME OFF THE INTERSTATE. I HAD THE TRUCK TOWED TO THE FORD DEALER WHERE I PURCHASED IT. THEY DIAGNOSED IT AND SAID THERE'S METAL THROUGHOUT THE FUEL SYSTEM, THE HPFP IS GOING BAD AND WEARING OUT, THERE IS ALSO RUST AND WATER IN THE FUEL RAIL. IN ORDER TO FIX THE PROBLEM, THE BILL WILL BE A LITTLE OVER $11,000. IN DECEMBER RIGHT AFTER I BOUGHT THE TRUCK, I TOOK IT INTO THE FORD DEALER AND HAD THEM FULLY SERVICE THE TRUCK, CHECK THE OIL, CHANGE BOTH FUEL FILTERS, ETC. I HAVE ALL RECEIPTS TO SHOW FORD THAT I HAVE MAINTAINED THE TRUCK. I HAVE FULLY MAINTAINED THE TRUCK AND HAVE DRAINED THE WATER SEPARATOR MONTHLY SINCE I PURCHASED THE TRUCK. I HAVE DONE EVERYTHING ON MY PART TO MAKE SURE THE TRUCK IS WELL CARED FOR AND MAINTAINED. I HAVE NOW BEEN FIGHTING WITH FORD CORPORATE FOR 5 WEEKS NOW AND THEY ARE SAYING THIS ISSUE ISN'T COVERED BY WARRANTY. IT'S A SHAME THAT YOU BUY A TRUCK FROM THE FORD DEALER WITH A 100,000 MILE WARRANTY AND NOW FORD IS CLAIMING THAT THIS ISSUE ISN'T COVERED BY WARRANTY. THIS IS A KNOWN FAULTY FUEL PUMP THAT WEARS OUT PREMATURELY AND IS COSTING CONSUMERS TENS OF THOUSANDS OF DOLLARS TO REPAIR AND FORD WILL NOT STAND BEHIND THEIR WARRANTY! THIS IS A SHAME AND RIDICULOUS ON FORDS END!

NHTSA ID

11244230

Incident

Jul 12, 2019

Mileage

42,000 mi

HAD VEHICLE 8 MONTHS. DRIVING ON INTERSTATE 95 PULLING MY CAMPER, "LOW FUEL PRESSURE" LIGHT CAME ON, PULLED OVER IMMEDIATELY. SAW SMOKE, THEN FIRE. GOT OUT OF TRUCK WITH MY DOG AND CALLED 911. REPORT ATTACHED.

NHTSA ID

11220464

Incident

Apr 9, 2019

Mileage

90,000 mi

DIESEL EXHAUST FLUID REDUCTANT HEATER FAULT, CHECK ENGINE LIGHT HAS ILLUMINATED AND IS NOT COVERED UNDER PREVIOUS RECALLS. RECURRING PROBLEM FOR FORD SUPER DUTY THAT NEEDS TO BE EXTENDED FOR THIS MODEL AS IT IS THE SAME PROBLEM THAT PREVIOUS ATTENTION WAS GIVEN TO. IT IS A EMISSIONS PROBLEM THAT FAILS ON THESE TRUCKS.

NHTSA ID

11187014

Incident

Mar 7, 2019

Mileage

55,250 mi

TL* THE CONTACT OWNS A 2015 FORD F-350. WHILE DRIVING 45 MPH, THE VEHICLE STALLED AND THE ENGINE REDUCTION WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE HIGH PRESSURE FUEL PUMP NEEDED TO BE REPAIRED. THE VEHICLE WAS TOWED TO A LOCAL DEALER (DUNNING MOTOR SALES, 9108 SOUTHGATE RD, CAMBRIDGE, OH 43725, (740) 439-4465) WHERE IT WAS DIAGNOSED THAT THE HIGH PRESSURE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND PROVIDED CASE NUMBERS: CAS15099236 AND CAS15365409. NO FURTHER ASSISTANCE WAS PROVIDED. THE FAILURE MILEAGE WAS 73,000. *TT *JS

NHTSA ID

11114131

Incident

May 13, 2018

Mileage

73,984 mi

EXHAUST FILTER CLEANING WHEN THAT WARNING COMES ON MY TRUCKS ENGINE IS REALLY ROUGH AND SHAKES. THIS IS WHEN DRIVING TO CLEAR THE EXHAUST FILTER.

NHTSA ID

11111026

Incident

Jul 12, 2018

Mileage

52,576 mi

DEF TANK FILLED AT 7300 MILES. AT 9600 MILES A "EXHAUST FLUID LOW" 50 MILES TIL ENGINE IDLE. PICKED UP EXHAUST FLUID AND REFILLED-ONLY 2 GALS ADDED TO OVERFLOWING. DID NOT RESET, WENT TO STANLEY FORD KENAI, AK. COUNTDOWN WENT ON, THEN"ENGINE IDLE AT NEXT RESTART" DEALER SAYS TO BAD NOX SENSORS, REPLACED AND CODES CLEARED. 15 MILES LATER, EXHAUST SYSTEM FAILURE" ENGINE WILL IDLE SOON" FORTUNATELY I MADE IT HOME IN THE DARK AND 40 MILES IN THE RAIN. NOW IT HAS GONE INTO THE "ENGINE IDLE" MODE AND "CHECK YOUR MANUAL" DEALER CALLED, TOW TRUCK CALLED, SOON TO BE GOING BACK TO DEALER.

NHTSA ID

10893529

Incident

Aug 4, 2016

Mileage

9,675 mi

EXHAUST FLUID MESSAGE ON DASH THAT SPEED WILL BE LIMITED TO IN 50 MILES. WENT AND BOUGHT A NEW JUG OF BLUE DEF. IT TOOK 2 GALLONS TO FILL TO RUNNING OVER. THEN BEFORE I GOT TO THE KENAI, AK DEALER, IT SAYS ENGINE WILL IDLE UPON RESTART. THE KENAI, AK DEALER SAID UP AND DOWN STREAM NOX SENSORS HAD FAILED AND RESET THE CODES. 15 MILES LATER, I GET AND "EXHAUST SYSTEM FAILURE" ENGINE WILL IDLE SOON. MADE IT HOME(40 MILES AT 10PM AND RAINING) THEN IT SAYS ENGINE IDLED, CHECK OPERATOR MANUAL. BASICALLY IT THINKS MY DEF TANK IS EMPTY, BUT IT HAS ONLY 75 MILES ON A COMPLETELY FULL TANK.

NHTSA ID

10893458

Incident

Aug 4, 2015

Mileage

9,700 mi

2015 F350 6.7 DIESEL WITH 46,000 MILES THAT IS DOWN BECAUSE HPOP IS DEFECTIVE AND SPREADING MEDAL THROUGH SYSTEM. FORD HAS INSPECTED AND SAID IT IS BECAUSE OF WATER IN FUEL, EVEN THOUGH NO WARNING LIGHTS OR CODES ARE AVAILABLE. FORD PULLED SENSORS OUT OF ENGINE AND REJECTED REPAIR BECAUSE OF TARNISH ON SENSORS. THE ONLY CODES WERE FOR (LOW FUEL PRESSURE & REDUCED POWER). NO OTHER CODES. INITIAL INSPECTION REVEALED ABOUT 3/4 INCH OF WATER IN WATER SEPARATOR BUT NO LIGHT OR CODE. THE WARNINGS OCCURRED WHEN TRUCK WAS STARTED AND IT RAN ABOUT 100 FT BEFORE BEING SHUTDOWN AND TOWED TO DEALERSHIP. THIS APPEARS TO BE A COMMON PROBLEM SINCE FORD OFFERS A REPAIR KIT FOR THIS ISSUE. TOTAL COST OF REPAIR IS BETWEEN $9500,00 & $12,500 DOLLARS AND THIS ON A TRUCK WHICH IS STILL UNDER WARRANTY THAT FORD WILL NOT HONOR. THE TRUCK WASN'T A YEAR OLD UNTIL MAY 2016 AND HAS BEEN DOWN FOR OVER FOUR MONTHS BECAUSE FORD WILL NOT REPAIR. THIS IS THE BOSCH C4 SERIES PUMP. *BF *TR *DT CONSUMER STATED HE HAD THE TRUCK REPAIRED AND HE SOLD IT. *JB

NHTSA ID

10892303

Incident

Mar 1, 2016

Mileage

46,000 mi

DURING REGENERATION OF THE DIESEL PARTICULATE FILTER THE TRUCK LOSES POWER AND OPERATES ROUGHLY. THIS LAST OCCURRED AS I WAS MERGING INTO TRAFFIC ON THE HIGHWAY DURING SLICK ROAD CONDITIONS. THIS COULD HAVE VERY EASILY RESULTED IN LOSS OF TRACTION AND/OR COLLISION AS I WAS UNABLE TO ACCELERATE TO SPEED.

NHTSA ID

10819844

Incident

Dec 24, 2015

Mileage

5,100 mi

THE VEHICLE IS A DIESEL, AND WHEN IT ENTERS REGEN MODE TO CLEAN THE EXHAUST FILTER APP. ONE MINUTES AFTERWARD THE ENGINE ROUGHS VERY ROUGH AND WILL NOT ACCELERATE AT ALL. THIS CONTINUES FOR 2-3 MINUTES. THE TRUCK REMAINS RUNNING, BUT WILL PRESSING THE GAS PEDAL AT ALL RESULTS IN BUCKING AND SHAKING UNTIL I TAKE MY FOOT OFF THE PEDAL. THE ISSUE BEGAN AT AROUND 2500-3000 MILES, AND THERE ARE CURRENTLY 8400 ON THE TRUCK. IT HAPPENS EVERY TIME THE EXHAUST FILTER IS CLEANED.

NHTSA ID

10789072

Incident

Nov 5, 2015

Mileage

8,400 mi

WOULD NOT REGENERATE WHEN REQUIRED. WENT INTO FILTER FULL SERVICE NOW MODE. THEN CHECK ENGINE LIGHT CAME ON.

NHTSA ID

10767568

Incident

Sep 17, 2015

Mileage

12,272 mi